Processed slab with embedded optical elements

ABSTRACT

This document describes systems and process for forming processed slabs having embedded optical elements.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of and claims priority toU.S. application Ser. No. 15/674,192, filed on Aug. 10, 2017.

TECHNICAL FIELD

This document describes systems and processes for forming slab products,for example, a processed slab having one or more embedded opticalelements.

BACKGROUND

Stone slabs are a commonly used building material. Granite, marble,soapstone, and other quarried stones are often selected for use ascountertops due to their aesthetic properties. Stone slabs may also beformed from a combination of natural and other materials that canprovide improved qualities such as aesthetic characteristics,reproducibility, and stain-resistant or heat-resistant properties.

SUMMARY

Some embodiments described herein include processed slabs with embeddedoptical elements suitable for use in living or working spaces (e.g.along a countertop, table, floor, or the like), and systems andprocesses for forming such slabs. In particular embodiments, a processedslab includes embedded optical elements that are capable of transmittingvisible light to a surface of the slab. In some embodiments, the opticalelements can each have a length that is approximately equal to the slabthickness (e.g. and are capable of transmitting visible light between afront major surface and a rear major surface). For example, the opticalelements may have lengths such that the fibers do not extend beyond thefront major surface and the rear major surface. A light source can bedirected toward a first major surface of the processed slab to providelight that is transmitted through the slab to a second major surface.For example, the light source can be positioned rearward of the rearmajor surface of the processed slab to emit light toward the rear majorsurface that is then transmitted through optical elements to the frontmajor surface (e.g. without requiring one or more optical bundlesunderneath the rear major surface that are physically connected to alight source). Alternatively or additionally, a light source may bepositioned along a side or end of the slab, and the optical elements maybe positioned to transmit light from the side or end of the slab to afront surface, rear surface, and/or another side or end of the slab.

The processed slab can be formed from a particulate mineral mix (or acombination of differently pigmented particulate mixes) and vibrated andcompacted in a slab mold. In some embodiments, the optical elements arepositioned in the pigmented particulate mineral mix that is dispensedinto a mold. The pigmented particulate mineral mix and the opticalelements arranged in the mold are then vibrated and compacted to form aprocessed slab. The front major surface of the slab can be polished toform a smooth surface (e.g. a smooth surface formed by the moldedparticulate and ends of the optical elements) and allow lighttransmitted through the embedded optical elements to be visible at thefront major surface.

Implementations may include one or more of the following optionalfeatures. For example, particular embodiments described herein include aprocessed stone slab, including a front major surface and a rear majorsurface, the front and rear major surfaces at least 2 feet wide by atleast 6 feet long and extending perpendicularly to a slab thickness, anda plurality of optical elements each having a first end, a second end,and a length between the first end and the second end. The length ofeach optical element may be parallel (e.g. approximately parallel within30% of exactly parallel) and equal (e.g. approximately equal within 15%of exactly equal) to the slab thickness, and each optical element iscompletely surrounded by the particulate mineral mix between the firstand second ends.

In some implementations, the system can optionally include one or moreof the following features. The optical elements may allow transmissionof light between the front major surface and the rear major surface dueto total internal reflection. The plurality of optical elements mayinclude fiber optic cables. The front major surface may be defined bythe particulate mineral mix and first ends of the plurality of opticalelements. The front major surface and/or back major surface may be apolished surface. Each of the plurality of optical elements may bearranged within the processed slab according to a predetermined array.The slab may further include a light source configured to transmit lightbetween the front major surface and the rear major surface through atleast one of the plurality of optical elements between the first andsecond ends. The particulate mineral mix may include predominantlyquartz.

Some embodiments described herein include a processed article, includinga processed slab having a front major surface and a rear major surface,the front and rear major surfaces at least 2 feet wide by at least 6feet long and extending perpendicularly to a slab thickness, a pluralityof optical elements having a length between first and second ends, and acarrier web connected to the processed slab at least partially by theplurality of optical elements. The optical elements are each attached tothe carrier web in a fixed array proximate the first ends, and extendcompletely through the slab thickness in a direction parallel to theslab thickness.

In some implementations, the system can optionally include one or moreof the following features. The article may include a light sourceconfigured to transmit light through at least one of the plurality ofoptical elements between the first and second ends by total internalreflection. The processed slab may include quartz. The plurality ofoptical elements may include fiber optic cables. Each of the pluralityof optical elements may be arranged within the processed slab accordingto a predetermined array. The carrier web may be configured to beseparable from the processed slab.

Some embodiments described herein include a process of forming aprocessed slab, including dispensing a pigmented particulate mineral mixinto a slab mold, positioning a plurality of optical elements within theslab mold parallel with a mold thickness, contemporaneously vibratingand compacting the pigmented particulate mineral mix and plurality ofoptical elements arranged in the mold so as to form a processed slabthat is generally rectangular and has a front major surface and a rearmajor surface, and polishing the front major surface and/or rear majorsurface of the slab. The plurality of optical elements each have alength between first and second ends, and wherein the length of eachoptical element is parallel and equal to the slab thickness such thatthe first end is visible at the front major face and the second end isvisible at the rear major face.

In some implementations, the system can optionally include one or moreof the following features. The plurality of optical elements may allowpassage of light between the front major surface and the rear majorsurface by total internal reflection. The step of dispensing thepigmented particulate mix may be performed after the step of positioninga plurality of optical elements within the slab mold. Positioning theplurality of optical elements in the mold may include inserting theoptical elements into the pigmented particulate mineral mix within themold. The process may include inserting a projection into the pigmentedparticulate mineral mix to form a hole in the pigmented particulate mix,and wherein the step of positioning the plurality of optical elements inthe mold comprises inserting an optical element into the hole. The frontmajor surface may be defined by the pigmented particulate mix and firstends of the optical elements.

Some embodiments described herein include a processed slab including afront major surface and a rear major surface, the front and rear majorsurfaces at least 2 feet wide by at least 6 feet long and extendingperpendicularly to a slab thickness defined by a particulate mineralmix, and a plurality of means for transmitting light between the frontmajor surface and the rear major surface, the plurality of means fortransmitting being oriented substantially parallel to one another.

In some implementations, the system can optionally include one or moreof the following features. Each means for transmitting may include afiber optic cable having a first end, a second end, and a length betweenthe first end and the second end, wherein the length of each fiber opticcable is parallel and equal to the slab thickness. Each fiber opticcable may be completely surrounded by the particulate mineral mixbetween the first and second ends.

The articles, systems, and techniques described herein may provide oneor more of the following advantages. First, some embodiments describedherein provide a stone slab having a plurality of embedded opticalelements that add visual appeal to the stone slab. The stone slab may beused as a countertop, work surface, wall covering, floor covering, etc.,that is capable of transmitting light through the thickness of a slab atdiscrete locations. For example, ends of optical elements may be visibleon a surface such that light transmitted though the optical elements isvisible on the surface.

Second, some embodiments described herein facilitate light transmissionthrough a slab via optical elements that have a thickness similar to thethickness of the stone slab (e.g. less than or equal to the thickness ofthe stone slab such that the optical elements do not extend externallyfrom the slab). The stone slab may thus include smooth and/or polishedsurfaces, and the optical elements may not be immediately noticeablewhen light is not being transmitted through the optical elements and/ormay not be immediately felt (e.g. because the optical elements form partof the smooth and/or polished surface).

Third, some embodiments described herein facilitate handling,transportation, and storage of stone slabs having embedded opticalelements. For example, slabs may be stacked or handled without the needto handle external optical elements, such as external portions of fiberoptic cables extending outward from a surface of the stone slab.

Fourth, some embodiments facilitate the placement of optical elementsinto a slab mold prior to forming a hardened slab. The finished slab maythus have optical elements that are embedded according to apredetermined array with minimal adjustments to the slab formationprocess and/or without requiring a permanent skeleton or grid that ispermanently embedded within the finished slab.

Fifth, some implementations described herein provide an internal supportstructure that facilitates placement of optical elements along apredetermined and/or repeatable array within a slab mold. The internalsupport structure may be used to reduce movement of the optical elementsfrom an initial placement during the slab formation process (e.g. if thepositioning and/or orientation of the mold is adjusted during, forexample, compaction and curing of a pigmented particulate mineral mix).

Sixth, some implementations described herein facilitate therepeatability of embedding optical elements according a predeterminedarray. For example, a carrier may efficiently secure the position andorientation of a plurality of optical elements within a mold.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other potentialfeatures and advantages will be apparent from the description, thedrawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are a front view and a side view of an example of aprocessed slab with embedded optical elements.

FIG. 1C is a front view of the processed slab of FIG. 1A with lighttransmitted through the embedded optical elements.

FIG. 1D is a top view of an example of a processed slab with embeddedoptical elements arranged in different arrays.

FIGS. 2A and 2B are exploded and assembled views of an example of ahorizontal slab mold used to form a processed slab, in accordance withsome embodiments.

FIG. 2C is a perspective view of an example of a processed slab withembedded optical elements that is formed using the slab mold illustratedin FIGS. 2A and 2B.

FIG. 3A is a perspective view of an example of a vertical slab mold usedto form a processed slab, in accordance with some embodiments.

FIG. 3B is a top view of an example of a processed slab with embeddedoptical elements that is formed using the slab mold illustrated in FIG.3A.

FIGS. 4A and 4B are top and side views of an example of a carrierapparatus that is used to secure and insert optical elements into apigmented particulate mineral mix, in accordance with some embodiments.

FIG. 5 is a top view of an example of a processed slab with embeddedoptical elements that are secured using an internal structure during theslab formation process.

FIG. 6 is a side view of an example of a carrier arm that can be used toautomatically insert optical elements into a pigmented particulatemineral mix.

FIG. 7 is a perspective view of a processed slab with embedded opticalelements.

FIG. 8 is a flow diagram of an example process for a processed slabproduct with embedded optical elements.

In the drawings, like reference numbers represent corresponding partsthroughout.

DETAILED DESCRIPTION

Referring to FIGS. 1A-1C, an exemplary stone slab 110 is shown includingembedded optical elements 112. Slab 110 includes a front major surface110 a and a rear major surface 110 b. Front major surface 110 a and rearmajor surface 110 b are separated by a slab thickness (T) (e.g. athickness of the hardened stone slab 110). In various exemplaryembodiments, slab thickness (T) may be consistent at locations acrossthe front and rear major surfaces 110 a, 110 b (e.g. slab 110 may have auniform slab thickness (T)). Slab 110 may be made from one or moremineral materials or mixes, and the optical elements 112 are embedded inthe material(s) or mix(es) that make up slab 110. Slab 110 (e.g. a stoneslab or portion of a stone slab, such as a cut portion or partialremnant of a slab) may be a processed stone slab, tile, or the like, andmay be suitable for installation at one or more locations, including asa countertop, backsplash, reception desk, flooring, wall covering,divider, cabinet facing, veneer, pillar, surround (e.g. fireplacesurround), etc.

The optical elements 112 are arranged in an array within the slab 110.For example, optical elements 112 may be positioned according to apredetermined array such that the individual optical elements 112 arearranged according to a specified pattern. In various exemplaryembodiments, the predetermined array can be selected to provide apredetermined visual appearance, particularly when light is transmittedthrough optical elements 112. Alternatively or additionally, opticalelements 112 may be positioned randomly, or in an arrangement thatappears random, within slab 110. In an exemplary embodiment, opticalelements 112 have a substantially uniform density throughout slab 110(e.g. each quadrant of slab 110 having a uniform surface area has aboutthe same number of optical elements 112).

Slab 110 may be processed and/or cut to have a slab length (L) and aslab width (W), which in this embodiment defines front major surface 110a and rear major surface 110 b. For example, stone slab 110 may be arelatively large slab that may be cut to specific shapes for use inliving or working spaces (e.g., along a countertop, table, floor, or thelike). In various exemplary embodiments, stone slab 110 is at least 3feet wide by at least 6 feet long, for example between about 3 feet and18 feet wide and between about 6 feet and 24 feet long, or between about4.5 feet and 7 feet wide and between about 10 feet and 12 feet long. Insome exemplary embodiments, stone slab 110 is about 7 feet wide by about12 feet long. In other embodiments, stone slab 110 is about 4.5 feetwide (approximately 140 cm wide) by about 10 feet long (approximately310 cm long).

Stone slab 110 may be a processed stone slab (e.g. such as a moldedstone slab) including quartz and/or other particulate mineral materialthat, when mixed with pigments and a resin binder and compressed,provides a hardened slab product suitable for use in living or workingspaces (e.g., along a countertop, table, floor, or the like).Manufacturing stone slab 110 may include steps of dispensing one or moreparticulate mineral mixes in a mold, vibrating and/or compacting theparticulate mineral mixes, curing the compacted mix, polishing asurface, and/or other operations.

Stone slab 110 may be formed in a process in which one or moreparticulate mineral mixes are dispensed into a mold, vibrated,compressed, hardened, cut, and/or polished to produce a finished stoneslab. In some embodiments, one or more of the particulate mineral mixesused to form the stone slabs can include organic polymer(s) and aninorganic (mineral) particulate component. The inorganic (mineral)particulate component may include such components as silicon, basalt,glass, diamond, rocks, pebbles, shells, a variety of quartz containingmaterials, such as, for example, but not limited to: crushed quartz,sand, quartz particles, and the like, or any combination thereof. Insome embodiments, one or more particulate mineral mixes each comprisequartz as a predominant component, which may include sand of variousparticle sizes and of different combinations. In the resulting stoneslab, the organic and inorganic materials can be linked using a binder,which may include for example, monofunctional or multifunctional silanemolecules, dendrimeric molecules, and the like, that may have theability to bind the organic and inorganic components of the compositestone mix. The binders may further include a mixture of variouscomponents, such as initiators, hardeners, catalysts, binding moleculesand bridges, or any combination thereof. Some or all of the mixesdispensed in the mold may include components that are combined in amixing apparatus (not shown) prior to being conveyed to the mold. Themixing apparatus can be used to blend raw material (such as quartz,organic polymers, unsaturated polymers, and the like) at various ratios.For example, some or all of the mixes dispensed in the mold may includeabout 80-95% quartz aggregates to about 5-15% polymer resins. Inaddition, various additives, may be added to the raw materials in themixing apparatus, such additives may include, metallic pieces (e.g.,copper flecks or the like), colorants, dyes, pigments, chemicalreagents, antimicrobial substances, fungicidal agents, and the like, orany combination thereof.

After the mold has been sufficiently filled with the one or moreparticulate mineral mixes, the mold and/or its contents may be subjectedto one or more subsequent operations. For example, compaction pressure,vibration, and vacuum may be applied to the contents inside the filledmold, thereby converting the one or more particulate mixes into a slab.The filled mold (with the compacted and hardened slab therein) mayproceed to a curing operation during which the material used to form theslab (including any resin binder material) are cured via a heating orother curing process, thereby further strengthening the slab inside thefilled mold. After the slab is fully cured and sufficiently cooled, thehardened and cured slab may be removed from the mold.

In some embodiments, the hardened and cured slab may be polished to asmooth finish. The polishing step may reveal ends of optical elementsembedded within the slab, and/or produce a smooth surface in which endsof optical elements are flush with the hardened particulate surface suchthat discontinuities or rough edges are reduced.

In some exemplary embodiments, slab 110 may have one or more aestheticeffects (e.g. due to the visual appearance of one or more particulatemineral mixes), such as veins that extend partly or fully across acomplete length (L) of slab 110, through all or part of thickness (T),and/or positioned relative to one another based on a predeterminedpattern. The optical elements 112 may be arranged to complement anaesthetic effect of slab 110, such as the aesthetic effect due to thevisual appearance of one or more particulate mineral mixes. For example,slab 110 may include a first vein, second vein, and/or backgroundpattern, and the optical elements 112 may be arranged to enhance theappearance of an outline or boundary of the first and/or second veins byhaving a higher concentration along the outline or boundary of the vein.Alternatively or additionally, the distribution concentration of theoptical elements 112 may be selected such that the optical elements areonly present, or primarily present, in the first vein or the backgroundpattern by having a relatively higher distribution concentration in thefirst vein or background pattern and a relatively lower distributionconcentration in the second vein.

The optical elements 112 have characteristics that allow transmission oflight (e.g. visible light) between first and second ends of the opticalelement. In an exemplary embodiment, optical element 112 is a fiberoptic cable configured to carry light between first and second ends(e.g. by total internal reflection). Optical element 112 may include oneor more layers of different material composition. For example, opticalelement 112 may include a first layer 112 c and a second layer 112 dsurrounding (directly or indirectly) first layer 112 c. First layer 112c may be a core layer and second layer 112 d may be a cladding layerhaving a refractive index different than first layer 112 c such thatlight may be transmitted through the core due to total internalreflection, for example. In some exemplary embodiments, optical element112 may include one or more protective layers that protect first layer112 c and/or second layer 112 d from damage.

In some exemplary embodiments, light is transmitted through the opticalelement 112 due in part to a difference in refractive index between theoptical element 112 and the material of slab 110 (e.g. the particulatemineral mix that makes up the majority of slab 110). For example,optical element 112 may have a uniform material composition, and/ormaterials having similar refractive indices. Interaction between theoptical element 112 and the material of slab 110 facilitatestransmission of light as a result of total internal reflection. Invarious exemplary embodiments, optical element 112 comprises one or moreglass (e.g. silica glass) and/or polymer materials, such as polymethylmethacrylate, fluorinated polymers, etc. Optical elements 112 may behighly heat-resistant such that optical elements 112 can withstand heatapplied to the particulate mineral mix during manufacturing of slab 110without deformation, shrinkage, damage, etc. that significantly altersthe light transmission characteristics of optical elements 112.

The optical elements have geometry and dimensions that allowtransmission of visible light between front major surface 110 a and rearmajor surface 110 b of slab 110. In an exemplary embodiment, opticalelements 112 have a substantially cylindrical shape, and include firstand second circular ends 112 a, 112 b, separated by a length (L). Thecross-section of optical element 112 may be uniform (e.g. a circle ofconsistent area) between first and second ends 112 a, 112 b. In variousexemplary embodiments, the optical elements 112 have a diameter betweenabout 0.1 mm and 10 mm, 0.5 mm and 5.0 mm, or about 2.0 mm. Suchdiameters provide effective transmission of visible light for affectingthe aesthetic appearance of slab 110, while facilitating a smoothsurface. In some embodiments, optical elements 112 may have an oval,elliptical, square, parallelogram, polygon, etc. In some embodiments,various optical elements 112 embedded in slab 110 may have differentshapes and sizes, and the shapes and sizes of optical elements 112 maybe selected to affect the visual appearance of slab 110.

Length (L) of optical elements 112 may be equal to thickness (T) of slab110 (FIG. 1B). Such relative dimensions of optical elements 112 and slab110 allow first and second ends 112 a, 112 b to extend through theentire thickness (T) of slab 110 such that the optical elements arevisible (e.g. when light is transmitted through optical elements 112)from the front major surface 110 a and the rear major surface 110 b, yetremain within the slab 110 such that portions of the optical elements112 (e.g. along the length (L) between first and second ends 112 a, 112b) do not extend externally beyond the front or rear major surfaces 110a, 110 b of slab 110. In such embodiments, front major surface 110 a andrear major surface 110 b may be oriented substantially perpendicular tothe slab thickness (T), and the optical elements 112 are substantiallyparallel to the slab thickness (T). For example, the optical elements112 may be completely surrounded by the particulate mineral mix of slab110 between first and second ends 112 a, 112 b.

A length (L) of optical elements 112 that is equal to (or less than) thethickness (T) may facilitate handling, transportation, storage, andinstallation of slab 110, while being able to provide light transmissionbetween front and rear major surfaces 112 a, 112 b. For example, in someembodiments, external optical elements that would otherwise need to becollected and/or bundled are avoided. Alternatively or additionally,optical elements 112 can transmit light between front and rear majorsurfaces 112 a, 112 b without being directly connected to a light sourceor other structure external to slab 110.

In some exemplary embodiments, the first and second ends 112 a, 112 b ofoptical elements 112 are exposed. For example, the first and second ends112 a, 112 b form part of the front and/or rear major surfaces of slab110. The first and/or second ends 112 a, 112 b may be polished togetherwith the other portions of the front and/or back major surface toprovide a smooth, consistent surface. In some embodiments, a gloss levelbetween the first ends 112 a of optical element 112 and other portionsof front major surface 110 a are substantially similar such that thefirst ends 112 a are not immediately observable through casual viewingof the slab 110 when light is not transmitted through the slab 110, yetprovide a discrete location of light transmission when light istransmitted through the slab 110.

In some exemplary embodiments, the first and second ends 112 a, 112 b,are covered by particulate material of slab 110 (e.g. in configurationsin which optical elements 112 are parallel to a slab thickness and thelength (L) is less than the slab thickness, or the optical elements areangled relative to the slab thickness). Optical elements 112 that arenot exposed at first and/or second ends 112 a, 112 b may facilitatetransmission of light through slab 110 while promoting a smooth surfaceand/or that reduces the visible appearance of optical elements 112 whenlight is not actively transmitted through slab 110. In some embodiments,the location of first and/or second ends 112 a, 112 b relative to anexposed surface of slab 110 may be selected to affect the visual effectcreated by optical elements 112. For example, first and/or second ends112 a, 112 b embedded deeper within slab 110 may result in relativelyless light transmission, or no light transmission, observable at asurface of the slab, or result in a more diffuse appearance, and firstand second ends 112 a, 112 b, near or exposed at a surface of slab 110may result in relatively greater light transmission observable at asurface, or result in a more discrete light.

Referring still to FIG. 1B, a light source 120 may be positioned todirect light toward rear major surface 112 b (e.g. positioned underneaththe slab 110). The light source 120 provides light for transmissionthrough the slab thickness (T) of the slab 110 via the optical elements112 such that the light is visible at the front major surface 110 a ofthe slab 110. In various exemplary embodiments, light source 120 may bepositioned to direct light from rear surface 110 b to a side surface 110c, between two side surfaces 110 c, etc.

The light source 120 can be any type of suitable device that produceslight. In some embodiments, the light source 120 is a light source thatproduces diffuse light, and may include a fluorescent, incandescent,LED, halogen, or tungsten light source, or the like, for example. Inaddition, the light sources 120 can be capable of using scatteringtechniques to increase the spread of light toward the rear major surface110 b of the slab 110 such that a greater number of optical elements 112receive light, and/or a relatively consistent intensity of light, whichin turn can be transmitted through the slab thickness. The light may beemitted at discrete locations of slab 110 through the first ends 112 aof optical elements 112 such that the light is visible at the frontmajor surface 110 a. In some embodiments, light is substantially diffuseadjacent rear major surface 110 b, while discrete points of light arevisible on the front major surface 110.

For example, slab 110 may be installed as a countertop positioned abovea cabinet or other enclosure that at least partially supports slab 110.A diffuse light source, such as a light bulb, may illuminate theenclosure below slab 110, while discrete points of light are visible onthe exposed front major surface 110 a of slab 110. The aesthetic effectmay be enhanced when the level of ambient lighting of the environmentthat slab 110 is situated in is relatively low.

Light source 120 may be configured to vary one or more characteristicsof its light output during operation. In various exemplary embodiments,light source 120 may be configured to vary the color, color temperature,intensity, duration, direction, and/or other characteristics of light,which in turn may vary the color, temperature, intensity, duration,direction or other characteristics of light emitted at discretelocations on front major surface 112 a of slab 110. For example, thedirection, duration, and/or intensity may be varied to create atwinkling effect on front major surface 110 a.

Alternatively or additionally, light source 120 may be coordinated withone or more other systems that affect the environment where slab 110 isinstalled. For example, light source 120 may be programmed to outputlight that matches the volume, rhythm, etc. of music or audio in theinstallation environment, pressure applied to the slab 110 orsurrounding surfaces, etc. to create the effect of an active surface. Insome embodiments, slab 110 may be configured to respond to one or moreinputs to function as a smart surface. For example, light source 120 maybe adjustable to alter the characteristics of light transmitted throughslab 110, and may be adjustable by one or more user inputs. In anexemplary embodiment, slab 110 includes an optical-touch inputconfigured to receive an input by a user touching slab 110. A user maytouch a surface of slab 110 to toggle the light source 120 on and off,press or hold a surface of slab 110 to dim or increase the intensity oflight source 120, tap a surface of slab 110 to alter the color of lightsource 120, etc. In some embodiments, the distribution concentration ofthe optical elements is relatively high and sufficient to display movinggraphics or videos that a user may interact with (e.g. such as a userwould interact with a tablet computing device).

Referring to FIGS. 1A and 1C, the visual appearance of slab 110 may bealtered by changing the light that is transmitted through opticalelements 112. In a first configuration (FIG. 1A), a light source is notactive and little or no light is transmitted through optical elements112 (e.g. only ambient light transmitted through the optical elements112). Optical elements 112 may not be immediately visible, and may notsignificantly affect the aesthetic appearance of slab 110. For example,the characteristics of the pigmented material mix(es) that make up themajority of slab 110, and/or any veins, patterns, etc. resulting fromthe pigmented material mix(es) provide the primary aesthetic appearance.In a second configuration, a light source outputs visible light that istransmitted through one or more optical elements 112. The aestheticappearance of slab 110 is changed such that discrete points of light arevisible at the locations of optical elements 112. Other locations (e.g.where optical elements 112 are not present) may be substantially opaqueand/or transmit less or no light relative to optical elements 112.

In some exemplary embodiments, the distribution concentration andarrangement of optical elements 112 may provide a selected aestheticappearance both when a light source is not active and when a lightsource actively transmits a relatively high level of light through theoptical elements 112. For example, a relatively high distributionconcentration of the optical elements 112 may result in a relativelyhigh volume of the optical elements relative to particulate matter. Thecolor (or absence of color) of the optical elements 112 may thus affectthe overall visual appearance of the slab even when little light istransmitted through the optical elements 112 (e.g. a light source is notactively transmitting light through the optical elements 112). In someembodiments, the color of the surrounding particulate matter may be madedarker (e.g. when the optical elements 112 are clear or lighter) tomaintain a particular overall appearance. Alternatively or additionally,the optical elements 112 may be arranged to provide a design, logo,symbol, words, etc. that are readily perceivable both when a lightsource is actively transmitting light through the optical elements 112and when little light is transmitted through optical elements 112.

Referring to FIG. 1D, a slab 120 with embedded optical elements arrangedin different arrays 122 a, 122 b, 122 c, 122 d, and 122 e is shown. Slab120 includes embedded optical elements that are arranged in variouspatterns (e.g., a square 122 a, a circle 122 b, a triangle 122 c, anumber 122 e, a letter 122 d). Each of the arrays 122 a, 122 b, 122 c,122 d, and 122 e can be formed by positioning individual opticalelements according to a predetermined array prior to forming a hardenedslab. For example, the optical elements can be arranged according to apredetermined array within a slab mold before the particulate mix iscured to form a hardened slab (e.g. before or after particulate mineralmix is dispensed into the mold). The mixture and the arranged opticalelements can then be processed to form a hardened slab in which theoptical elements are embedded in an array that corresponds to thearrangement within the slab mold.

In some embodiments, the optical elements can be arranged such that theoptical elements provide a predetermined visual impression when light istransmitted through the slab 120. For example, the optical elements maybe arranged to provide the visual appearance of a logo, word(s), image,and/or other graphical feature. In some embodiments, the opticalelements may be arranged to complement a graphic or other aestheticprovided by slab 120. For example, an image or logo may be provided on asurface of the slab 120 (e.g. formed from the particulate mineral mix,painted, printed, applied, etc.), and one or more optical elements mayprovide a discrete light at a particular location, such as the eye of acharacter in the graphic, a star in a constellation, or other graphicalelement.

Referring now to FIGS. 2A and 2B, exploded and assembled views of a slabmold 200 are shown. Slab mold 200 includes a first slab mold portion 210and a second slab mold portion 220. The slab mold 200 includes a planarmold floor bounded by a collection of mold walls 203 extendingperpendicular from the planar mold floor, defining a general tray-likeshape where a pigmented particulate mineral mix 230 may be contained(e.g. after being dispensed from one or more collection hoppers, forexample). The second slab mold portion 220 may be joined with the firstslab mold portion 210 to form a mold cavity that contains theparticulate mineral mix 230 during subsequent vibro-compaction and/orcuring operations. In various exemplary embodiments, one or more of themold walls may be formed as part of first slab mold portion 210 and/orsecond slab mold portion 220.

The slab mold 200 may be formed at least partially of a polymer (e.g.including a flexible or elastomeric material), paper, wood, metal, or acombination thereof. The slab mold 200 includes walls 203 that at leastpartially define a cavity having a length and a width that approximatesthat of the slab to be formed. In some embodiments, the slab mold 200can define a cavity having a thickness of at least between about 0.25in. and 12 in., 0.5 in. and 6 in., or about 3 in.

The slab mold 200 may facilitate formation of a processed slab havingembedded optical elements, such as the processed slab 110 havingembedded optical elements 110 shown in FIGS. 1A-1C. In an exemplaryembodiment, one or more particulate mineral mixes 230 are dispensed intothe first slab mold portion 210 (e.g. into the cavity bounded by walls203). A carrier 240 is then moved toward the mix 230 in first moldportion 210 such that optical elements 212 carried by carrier 240 arepushed into mix 230. For example, carrier 240 brings optical elements212 into contact with mix 230, and/or pushes the optical elements 212into mix 230 such that at least a portion of each optical element iscompletely surrounded by the mix 230.

Carrier 240 may maintain optical elements 212 in a predetermined array,and/or provide additional rigidity to facilitate insertion of opticalelements into mix 230. For example, the optical elements 212 may beloaded to the protrusions 242 of carrier 240, and pressed into the mix230 by the protrusions 242. In some exemplary embodiments, protrusions242 provide a substantially rigid pin that facilitates insertion intothe particulate mix. Alternatively or additionally, protrusion 242 mayat least partially surround optical elements 212 (e.g. in the form of asleeve) to facilitate insertion of the optical elements 212 into the mix230.

In an exemplary embodiment, projections 242 are arranged on a majorplanar surface of carrier 240. Multiple projections 242 and opticalelements 212 may be inserted into mix 230 simultaneously. For example,carrier 240 may be brought into contact with mix 230 by bringing theentire carrier 240 into contact with the entire surface of mix 230 inmold 200. In other exemplary embodiments, carrier 240 may be rolledacross mix 230, or otherwise brought into contact individually or ingroups (e.g. as carrier 240 is moved across the exposed surface of mix230).

After the optical elements 212 are surrounded by the mix 230, the slabmold 200 is assembled by joining first slab mold portion 210 with secondslab mold portion 220 (e.g. as shown in FIG. 2B). In some embodiments,carrier 240 and second slab mold portion 220 are brought together withfirst mold portion 210 as a singular unit (e.g. and carrier 240 may bepart of second slab mold portion 220 itself). Alternatively, carrier 240may first bring optical elements 212 into contact with mix 230, andsecond slab mold portion 220 may subsequently be joined with first slabmold portion 210.

Referring now to FIG. 2B, an assembled slab mold 200 is shown. Theoptical elements 212 are positioned at least partially within mix 230such that at least a portion of the optical elements 212 are completelysurrounded by mix 230. In some embodiments, optical elements 212 arecompletely embedded within mix 230 such that the mix 230 covers ends ofoptical elements 212 and completely surrounds the optical elements 212between the ends.

In some embodiments, the assembled slab mold 200 can be used insubsequent operations to form a processed slab having embedded opticalelements. For example, the mix 230 and the optical elements 212 can becontemporaneously vibrated and compacted within the assembled slab mold200 to form a processed slab that has substantially same dimensions asthe inner dimensions of the mold 200 (e.g., defined by walls 203 and theheight of the mold 200). The resulting slab is thus formed with theoptical elements 212 embedded in a particular array similar to the arrayof protrusions 242, for example. Accordingly, the protrusions 242, andoptical elements 212 loaded to the protrusions 242, may be arranged inany predetermined array or pattern based on a desired array or patternof the optical elements 212 within the final processed slab.

In some embodiments, carrier 240 may form a layer in an intermediatestructure that may be removed or separated to form a finished stoneslab. For example, after the vibro-compaction and/or curing operations,carrier 240 may remain affixed to the resulting slab. Carrier 240 may besubsequently separated by cutting and/or grinding carrier 240 away fromthe slab to produce a smooth surface of the finished stone slab.

In some embodiments, carrier 240 may be removed before the mix 230 isformed into a hardened slab. For example, carrier 240 may be movedtoward the first slab mold portion 210 such that optical elements 212are positioned at least partially with the mix 230. The optical elements212 are then detached from carrier 240, for example, by mechanicallydecoupling, pneumatically decoupling, etc. In some embodiments, a forcejoining optical elements 212 with carrier 240 is less than a forcebetween optical elements 212 and mix 230 such that, after being pushedinto mix 230, the optical elements remain in mix 230 when carrier 240 ismoved in a direction away from mix 230. The second slab mold portion 220may then be joined with first slab mold portion 210 to enclose the mix230 and optical elements 212 within the mold cavity.

Referring to FIG. 2C, a processed slab 215 with embedded opticalelements 212 formed using the slab mold 200 is shown. The dimensions ofthe slab 215 are substantially similar to the dimensions defined by thewalls 203 of the mold 200. Major surface 215 a may result from polishingand/or removing a portion of carrier 240 such that optical elements 212are visible on the major surface 215 a of the slab 215 (e.g. when lightis transmitted through optical elements). In some embodiments, after themixture 230 within the mold 210 has been vibrated and compacted to forma processed slab, protrusions 242 of carrier 240 and/or a top portion ofthe slab may be cut and/or otherwise removed. Alternatively oradditionally, the major surface 215 a may be polished until entirely allof carrier 240 is removed from the processed slab 215. As depicted inFIG. 2C, removal of remaining portions of carrier 240 provides a cleanfront major surface 215 a such that optical elements 212 may be visibleon the front major surface 215 a.

Referring to FIG. 3A, a perspective view of an example slab mold 300 isdepicted, while particulate mix is dispensed while the slab mold 300 isin a non-horizontal orientation (e.g. angled 15°, 30°, 45°, 60°, 75°,90°, etc. from horizontal). The mold 300 is oriented non-horizontallyduring dispensation of a particulate mineral mix 330 and/or opticalelements 312 into the mold 300. For example, the mold 300 can include ashell portion that at least partially defines a space (shown in dashedlines in FIG. 3A) for receiving the mix 330 via an upwardly facingopening 302 of the mold 300. The mix 330 can be dispensed from one ormore separate conveyer lines that transport the mix 330 to a regionabove the opening 302 so that the mix 330 is then vertically poured intothe mold 300. The mold 300 can be formed of a structure that includes apolymer (e.g. including a flexible or elastomeric material), paper,wood, metal, or a combination thereof.

In some embodiments, the mold 300 can be vertically oriented duringdispensation of the mix 330 such that a major surface of the mold 300 ispositioned in a vertical position (e.g., 80 degrees from the horizontal+/−10 degrees). The poured mix 330 accumulates over previously pouredmix. In an exemplary embodiment, the mold 300 at least partially definesa length L and a width W of a hardened slab to be formed (because themold 300 retains the mix 330 therein throughout the subsequentcompaction and curing processes).

The slab mold 300 may be used to form a processed slab with embeddedoptical elements, such as a processed slab having one or more featuresand characteristics similar to processed slab 110 depicted in FIG. 1A.During dispensation of the mix 330 into mold 300, one or more carriers330 a, 330 b, 330 c may be inserted into the mold 300 to arrange opticalelements into the dispensed mix 330 at specified vertical positions.Each of the carriers 330 a, 330 b, 330 c secures one or more opticalelements (e.g. between 1 and 1000, 10 and 500, or about 100 opticalelements) along the length of the carrier 330 a, 330 b, 330 c. Forexample, the carriers may hold a selected number of optical elementsalong a length (e.g. corresponding to a length (L) of mold 330).Carriers 330 a, 330 b, and 330 c each hold five optical elements alongthe length L of the mold 300. In some exemplary embodiments, carriers330 a, 330 b, 330 c may be configured similar to a bandolier.

Each carrier 330 a, 330 b, 330 c may be inserted into the mold 300through the opening 300 at a specified time point during thedispensation of the mix 330 to create a desired vertical displacement hbetween each successive carrier that is inserted. For example, theselected vertical displacement h can be increased by increasing thedelay in time between when successive carriers are inserted into themold 300. In some embodiments, a consistent displacement h is maintainedbetween each successive carrier. In other embodiments, displacement h isvaried between each successive carrier, and/or displacement h may berandom or have the appearance of being random.

Carriers 330 a, 330 b, 330 c may be configured to maintain the opticalelements in a particular orientation relative to a thickness of the moldcavity. In an exemplary embodiment, carriers 330 a, 330 b, 330 c may beinserted in a particular orientation such that the optical elementssecured by the carriers 330 a, 330 b, 330 c are substantially parallelto the thickness of a slab to be formed by the mold 300. For example,the carriers 330 a, 330 b, 330 c can be initially oriented such that thelengths of the secured optical elements are parallel to the height ofmold 300 before insertion into the mold 300 (e.g. as shown by carrier330 a). After the carriers 330 a, 330 b, 330 c are inserted through theopening 302, the orientation may be adjusted (e.g. indirectly due toforces from the mix 330 being dispensed) such that optical elements areparallel to the thickness of mold (e.g. as shown by carriers 330 a and330 b). In some embodiments, carriers 330 a, 330 b, and/or 330 c may beinserted in a particular orientation such that the optical elementssecured by the carriers 330 a, 330 b, and/or 330 c are maintained in aselected orientation non-parallel to the thickness of a slab to beformed by the mold 300. A non-parallel orientation may be selected toaffect the aesthetic that results from the optical elements, forexample.

In some optional embodiments, multiple different mixes can be dispensedinto the mold 300. In such embodiments, different conveyer lines can beused to transport respective mixes according to a predefined patternsuch that the different particulate mixes pour into the mold 300according to a predetermined series of successive layers, some or all ofwhich can form veins in a slab that is formed using the mold 300.Optionally, each of the successive layers of the different mixes can bedispensed in different amounts, thereby providing differently sized andpositioned veins or striations. Furthermore, each individual layer maybe differently sized at one end of the mold 300 compared to the otherend of the mold 300, thereby further enhancing the complex striationsand veining patterns in a hardened slab that is formed using the mold300.

In an exemplary embodiment, after the dispensation of the mix 330 hasbeen completed, the mold 300 may be shifted to a horizontal orientationfor subsequent compaction and curing operations. For example, duringthese operations, the mixture and the optical elements within the mold300 are compacted together such that the mold 300 defines a generallycontinuous thickness.

Referring now to FIG. 3B, an example of a processed slab 330 formed withthe mold 300 is depicted. In some embodiments, the thickness of the slab330 is at least 0.2 cm, between about 0.2 cm and 5 cm, and preferablyabout 3 cm. As shown, the processed slab 330 includes, within itsinternal structure, carriers 330 a, 330 b, and 330 c, which wereinserted into the mold 300 during the dispensation of the mix 330 intothe mold 300 through the opening 302. In an exemplary embodiment, thecarriers 330 a, 330 b, and 330 c are not visible on the front and rearmajor surfaces of the processed slab 330. The ends of the opticalelements 312 that are secured by the carriers are visible on the frontand rear major surfaces (e.g. because their lengths are substantiallyequal to the thickness of the processed slab 330).

Referring to FIGS. 4A and 4B, top and side views of a carrier 430 areshown. The carrier 430 may include a polymer (e.g. including a flexibleor elastomeric material), paper, wood, metal, or a combination thereof,such that carrier 430 may maintain one or more optical elements in adesired orientation. The carrier 430 includes a body 431 (e.g. a frame),and one or more holding structures 432 which may secure an opticalelement 412 to be embedded into the particulate mix.

In some embodiments, the carrier 430 can be used to secure opticalelements 412 as they are positioned into a mineral mix, and may beparticularly advantageous when dispensing into a vertically orientedslab. For example, optical elements 412 may be secured by holdingstructures 432 defining openings sized to accommodate optical elements412.

In an exemplary embodiment, carrier 430 includes a plurality of holdingstructures 432 arranged linearly, and the length of the carrier 430 maybe similarly or slightly less than the length of a mold, such as mold300. Alternatively or additionally, the size of carrier 430, andparticularly holding structures 432, may be selected to be sufficientlysmall that the carrier is not visible in the finished stone slab anddoes not substantially reduce the structural integrity of the finishedstone slab.

Referring to FIG. 5, a top view of an example of a processed slab 510including embedded optical elements 512 and an internal structure 530 isshown. Internal structure 530 may include one or more body portions 531and one or more holding structures 532. For example, the internalstructure 530 can include a rigid body attached to a set of holdingstructures 531 having features and characteristics similar to the body431 and holding structures 432 of carrier 430 (FIGS. 4A and 4B).

During an exemplary slab formation process, optical elements 512 may beinitially secured in the holding structures 532 of the internalstructure 530. The internal structure 530, together with the opticalelements 512 positioned at least partially within holding structures532, may be positioned within a pigmented particulate mineral mixdispensed into a slab mold (e.g. such as a slab mold depicted in FIG. 2Aor 3A). The dispensed particulate mix and internal structure 530 arethen treated to form a hardened slab (e.g., vibrated, compacted, andcured to form a hardened slab). The structure and orientation of theinternal structure 530 can be maintained during the compaction andcuring processes. After the hardened slab has been formed, the opticalelements 512 are embedded within the hardened slab in the position andorientation in which they were secured by the internal structure 530.

Referring to FIG. 6, a side view of an example of a carrier 610 that canbe used to insert optical elements into a pigmented particulate mineralmix is shown. In an exemplary embodiment, carrier 610 may be configuredas a carrier arm (e.g. a robotic carrier arm) programmed to placeindividual optical elements (e.g. optical elements 612 a, 612 b) at aparticular location within the pigmented particulate mineral mix 630 inslab mold 650.

The carrier arm 610 includes a supply 611 of optical elements (e.g. thatprovide optical elements 612 a, 612 b, etc.). In an exemplaryembodiment, supply 611 comprises a spool of optical elements (e.g.optical element material that is not yet cut to size or separated intoindividual optical elements). The carrier arm 610 may feed material fromthe spool, and cut the optical element material to generate opticalelements of a predefined length (e.g. a length similar to the thicknessof the slab to be formed). The material may be cut before insertion intomineral mix 630, or may be cut to size after insertion into mineral mix630. In other exemplary embodiments, supply 611 may include a magazineof optical elements that are pre-cut to length and ready for insertioninto mineral mix 630.

The carrier arm 610 positions individual optical elements, such asoptical elements 612 a, 612 b, in specified locations of the slab mold650. Optical elements 612 a, 612 b may be placed based on apredetermined pattern to create a desired optical element array within aprocessed slab. For example, the robotic carrier arm 610 may beprogrammed to place optical elements at specified coordinate locationsalong the major surface of the slab mold 650 (e.g. corresponding to themajor surface of the slab to be formed) to form a particular pattern,logo, image, etc.

In some exemplary embodiments, carrier arm 610 inserts optical elementsin a multistep process. For example, in a first step, carrier arm 610may insert a rigid pin or projection into mix 630 to form an opening ordepression. In a second step, the optical element may be inserted intothe previously formed opening or depression.

Referring to FIG. 7, an exemplary slab 710 is shown including embeddedoptical elements 712. Slab 710 includes a front major surface 710 a, arear major surface 710 b, and side surfaces, such as side surfaces 710c. In various exemplary embodiments, slab 710 may have features similarto slab 110 described herein.

The optical elements 712 are arranged within the slab 710 such thatlight transmission between various locations of slab 710 is facilitated.In an exemplary embodiment, optical elements 712 are positioned tofacilitate light transmission from a light source 720 proximate sidesurface 710 c to front major surface 710 a. Multiple optical elements712 may be tightly distributed near light source 720, and extend throughslab 710 various distances, orientations, etc., to locations near frontmajor surface 710 a (e.g. spread across the front major surface). Inthis way, optical elements 712 may facilitate transmission of light froma relatively small area (e.g. near light source 720) to a relativelylarger area (e.g. across front major surface 710 a).

In various exemplary embodiments, light source 720 may be positionedproximate any of one or more surfaces of slab 710, and optical elements712 may be arranged to transmit light to any surface of slab 710. Insome embodiments, multiple light sources may be located near one or moresurfaces of slab 710, and optical elements 712 may be arranged totransmit light to the same or different surfaces of slab 710 (e.g. afirst set of optical elements 712 may be arranged to transmit lightbetween a light source proximate side surface 710 c to front majorsurface 710 a, and a second set of optical elements 712 may be arrangedto transmit light between a light source proximate side surface 710 d tofront major surface 710 a). Optical elements 712 and light source(s) 720may be arranged to provide a selected visual appearance, particularlywhen light is transmitted through optical elements 712.

Optical elements may be positioned linearly or having a curvaturethrough slab 710. For example, some optical elements 712 may be arrangedto extend between light source 720 and a location near front majorsurface 710 a substantially linearly (e.g. such optical elements 712 maybe relatively rigid). Alternatively or additionally, some opticalelements 712 may be arranged to curve between light source 720 and alocation near front major surface 710 a (e.g. such optical elements 712may be relatively flexible).

In some exemplary embodiments, slab 710 may be formed by a processinginvolving multiple stages if of distributing particulate mineral mixinto a mold and positioning optical elements 712. For example, a slabmold may be partially filled with a particulate mineral mix. The opticalelements may then be positioned within the particulate mineral mix (e.g.manually, automatically, via a carrier, etc.). After positioning opticalelements, additional particulate mineral mix may be distributed into themold to at least partially cover the optical elements. In someembodiments, these steps may be repeated to fill the mold and provide adesired arrangement of optical elements. The filled mold may thenadvance to one or more pressing and curing operations to form a hardenedslab.

FIG. 8 is a flow diagram of an example process 800 for forming aprocessed slab with embedded optical elements (e.g. such as slab havingfeatures and characteristics similar to slab 110 described herein). Insome embodiments, the process 800 may optionally be performed by a slabforming system that includes various conveyors that move a slab moldbetween different stations where each operation of the process 800 isperformed. The process 800 may include use of various types of slabmolds such as the mold depicted in FIG. 2A or 3A.

The process 800 may include the operation 810 of dispensing aparticulate mineral mix into a slab mold. For example, a dispensing headof a distributor can be configured to controllably release a particulatemineral mix through one or more apertures into the slab mold. Thedispensing head may be configured with a shutter or valve apparatus thatis controllable to regulate the flow of the particulate mineral mix fromthe dispensing head to the slab mold. The dispensing head may beadditionally controllable to dispense filler into the slab mold at asubstantially repeatable rate.

The process 800 can also include the operation 820 of positioning aplurality of optical elements in the particulate mineral mix. Theoptical elements may be positioned to be parallel with a mold thickness.In some embodiments, the plurality of optical elements are positioned inthe mix with a carrier that has protruding elements configured to holdthe optical elements and/or impart rigidity to facilitate insertion intothe particulate mineral mix. The protruding elements holding the opticalelements can be lowered into the mix. In other embodiments, theplurality of optical elements is positioned in the mix with the use of acarrier apparatus that secures the optical elements in holdingstructures, such as the carrier apparatus 400 shown in FIGS. 4A and 4B.Alternatively or additionally, the optical elements are positioned inthe mix with the use of a carrier that places individual opticalelements in specified locations within the slab mold based on apredetermined optical element arrangement.

The process 800 may also include the operation 830 of vibrating andcompacting the particulate mineral mix (e.g. contemporaneously vibratingand compacting the particulate mineral mix) and plurality of opticalelements in the mold so as to form a processed slab. The mixture withinthe mold, including the particulate mineral mix and the embedded opticalelements arranged within the mold, may be processed using a compressionmolding operation (e.g., vibro-compaction molding, curing, etc.). Duringthis operation, a slab mold can be encased with a top cover mold pieceand transported to a vibro-compaction station that applies compactionpressure, vibration, and vacuum to the contents inside the slab mold,thereby converting the particulate mix into a rigid slab.

In some embodiments, the process 800 may optionally include an operationof curing the compacted slab. For example, curing the compacted slab mayinclude curing the mineral mix via a heating process, thereby furtherstrengthening the slab formed inside the slab mold.

The process 800 can also include the operation 840 of polishing asurface of the processed slab. For example, after the curing operation840, the cured slab can be transferred to a polisher station where amajor surface of the slab is polished to a predetermined finish. One ormore front, back, or side surfaces may be polished at polisher station,and a degree of polish (e.g. the resulting gloss level, surface texture,etc.) may vary between one or more of the front, back, or side surfaces.In some embodiments, the polished or otherwise exposed major surface canprovide an outer appearance that is substantially repeatable. Polishingoperation 840 may include polishing and/or exposing one or both ends ofembedded optical elements to form a major surface of the finished stoneslab that has a consistent appearance substantially free fromdiscontinuities and/or that allows transmission of light through athickness of the slab at discrete locations of the optical elements.

Various operations of process 800 may be performed in any order. In anexemplary embodiment, the fiber optic elements may be positioned in themold, and some or all particulate mix to form the slab distributed intothe mold after the fiber optic elements are positioned. For example,embodiments described herein (e.g. with reference to FIGS. 1-7) may beformed in any suitable sequence, including positioning optical elementswithin the mold before the mold is filled with particulate mix. Theparticulate mineral mix, including embedded optical elements, may thenbe vibrated and compacted (e.g. in operation 830) so as to form aprocessed slab.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of anytechnology described herein or of what may be claimed, but rather asdescriptions of features that may be specific to particular embodiments.Certain features that are described in this specification in the contextof separate embodiments can also be implemented in combination in asingle embodiment in part or in whole. Conversely, various features thatare described in the context of a single embodiment can also beimplemented in multiple embodiments separately or in any subcombination.Moreover, although features may be described herein as acting in certaincombinations and/or initially claimed as such, one or more features froma claimed combination can in some cases be excised separate from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. Although a number of implementations have been described indetail above, other modifications are possible. For example, the logicflows depicted in the figures do not require the particular order shown,or sequential order, to achieve desirable results. In addition, othersteps may be provided, or steps may be eliminated, from the describedflows, and other components may be added to, or removed from, thedescribed systems. Accordingly, other implementations are within thescope of the following claims.

What is claimed is:
 1. A processed slab, comprising: a front majorsurface and a rear major surface, the front and rear major surfacesextending perpendicularly to a slab thickness defined by a particulatemineral mix, the particulate mineral mix made predominantly of a quartzmaterial mixed with a resin binder; and a plurality of fiber opticcables each having a first end, a second end, and a length between thefirst and second ends; wherein the length between the first and secondends of each of the fiber optic cables is surrounded by thepredominantly quartz particulate mineral mix and bound through the slabthickness by the resin binder, and wherein the first ends of the fiberoptic cables are exposed at the front major surface, and the second endsof the fiber optic cables are exposed at the rear major surface.
 2. Theprocessed slab of claim 1, wherein the particulate mineral mix includesbetween 80% and 95% quartz material.
 3. The processed slab of claim 1,wherein the front major surface comprises the particulate mineral mixand the first ends of the fiber optic cables, and the rear major surfacecomprises the particulate mineral mix and the second ends of the fiberoptic cables.
 4. The processed slab of claim 1, wherein the fiber opticcables allow transmission of light from the rear major surface to thefront major surface.
 5. The processed slab of claim 4, wherein the fiberoptic cables each include a core layer and a cladding layer, thecladding layer surrounding the core layer and having a refractive indexdifferent from that of the core layer.
 6. The processed slab of claim 5,wherein the fiber optic cables each include a protective layer thatprotects the cladding layer from damage.
 7. The processed slab of claim1, wherein the fiber optic cables are arranged such that the length ofeach fiber optic cable is parallel to the slab thickness.
 8. Theprocessed slab of claim 1, wherein each of the plurality of fiber opticcables is arranged within the processed slab according to apredetermined design.
 9. The processed slab of claim 1, wherein at leasttwo fiber optic cables of the plurality of fiber optic cables havedifferent cross-sectional shapes.
 10. The processed slab of claim 1,wherein at least two fiber optic cables of the plurality of fiber opticcables have different cross-sectional areas.
 11. The processed slab ofclaim 1, wherein the particulate mineral mix includes between 80% and95% quartz material.
 12. The processed slab of claim 1, wherein theoptical elements are arranged such that the length of each opticalelement is parallel and equal to the slab thickness.
 13. A processedslab, comprising: a front major surface and a rear major surface, thefront and rear major surfaces extending perpendicularly to a slabthickness defined by a particulate mineral mix, the particulate mineralmix made predominantly of a quartz material mixed with a resin binder;and a plurality of optical elements each having a first end, a secondend, and a length between the first and second ends; wherein each of theoptical elements is surrounded by the predominantly quartz particulatemineral mix between the first and second ends; and wherein the length ofeach optical element is equal to the slab thickness.
 14. The processedslab of claim 13, wherein each of the plurality of optical elements hasa uniform material composition between the first and second ends. 15.The processed slab of claim 13, wherein each of the plurality of opticalelements has a uniform cross-sectional shape between the first andsecond ends.
 16. The processed slab of claim 13, wherein each of theplurality of optical elements comprises a unitary layer that extendsentirely between the first and second ends.
 17. A processed slab,comprising: a front major surface and a rear major surface, the frontand rear major surfaces extending perpendicularly to a slab thicknessdefined by a predominantly quartz particulate mineral mix; and aplurality of optical elements each having a first end, a second end, anda length between the first and second ends, each of the optical elementsconfigured to transmit light that is directed towards the rear majorsurface, from the second end to the first end; wherein each of theoptical elements is surrounded by the predominantly quartz particulatemineral mix and bound through the slab thickness by the resin binderbetween the first and second ends, and wherein the first ends of theoptical elements are exposed at the front major surface, and the secondends of the optical elements are exposed at the rear major surface. 18.The processed slab of claim 17, wherein the front major surfacecomprises the particulate mineral mix and the first ends of the opticalelements, and the rear major surface comprises the particulate mineralmix and the second ends of the optical elements.
 19. The processed slabof claim 17, wherein the light that is directed towards the rear majorsurface is from an electrical light source that is configured to varyone or more characteristics of the light during operation, thecharacteristics including color, intensity, or duration.
 20. Theprocessed slab of claim 19, wherein the electrical light source isconfigured to vary the one or more characteristics of the light inresponse to music playing in an environment of the processed slab. 21.The processed slab of claim 19, wherein the electrical light source isconfigured to vary the one or more characteristics of the light inresponse to receiving input that indicates a user touch of the processedslab.
 22. A processed slab, comprising: a front major surface and a rearmajor surface, the front and rear major surfaces extendingperpendicularly to a slab thickness defined by a predominantly quartzparticulate mineral mix; and a plurality of optical elements each havinga first end, a second end, and a length between the first and secondends, each of the optical elements configured to transmit light that isdirected towards the rear major surface, from the second end to thefirst end; wherein each of the optical elements is surrounded by thepredominantly quartz particulate mineral mix between the first andsecond ends, and wherein the light that is directed towards the rearmajor surface is from an electrical light source that is configured toscatter the light such that locations of the rear surface where opticalelements are not present and each of the second ends of the opticalelements receive a relatively consistent intensity of light.